8 research outputs found
The capability enhancement of aluminium casting process by application of the novel CRIMSON method
The conventional foundry not only frequently uses batch melting, where the aluminium
alloys are melted and held in a furnace for long time, sometimes as long as a complete shift,
but also uses the gravity sand casting process where the molten aluminium alloys are
transferred using a ladle from furnace to pour station and are poured into a mould. During the
filling of the mould, the turbulent nature of the liquid metal gives rise to massive entrainment
of the surface oxide films which are the subsequently trapped into the liquid and act as micro
cracks. Also the long exposure time of the liquid surface to the surrounding environment
during melting, transferring and filling will increase the level of hydrogen absorption from
the atmosphere. The abovementioned factors are often the main reasons for casting defect
generation. In this paper the novel CRIMSON aluminium casting method is introduced which
has a number of advantages. Instead of gravity filling method, it uses the single shot upcasting
method to realize the rapid melting and rapid counter-gravity-filling mould operations
which reduce the contact time between the melt and environment thus reducing the
possibility of defect generation. Another advantage is the drastic reduction of energy
consumption due to shortened melting and filling time. A simulation software, FLOW-3D, is
used to compare this new method with the conventional gravity casting process. A tensile bar
case is used as a sample to simulate the filling process
The improvement of aluminium casting process control by application of the new CRIMSON process
All The traditional foundry usually not only uses batch melting where the
aluminium alloys are melted and held in a furnace for long time, but also uses
the gravity filling method in both Sand Casting Process (SCP) and Investment
Casting Process (ICP). In the gravity filling operation, the turbulent behaviour
of the liquid metal causes substantial entrainment of the surface oxide films
which are subsequently trapped into the liquid and generate micro cracks and
casting defects. In this paper a new CRIMSON process is introduced which
features instead of gravity filling method, using the single shot up-casting
method to realize the rapid melting and rapid filling mould operations which
reduce the contact time between the melt and environment thus reducing the
possibility of defect generation. Another advantage of the new process is the
drastic reduction of energy consumption due to shortened melting and filling
time. Two types of casting samples from SCP and ICP were compared with the new
process. The commercial software was used to simulate the filling and
solidification processes of the casting samples. The results show that the new
process has a more improved behaviour during filling a mould and solidification
than the two conventional casting processes
Improvements in energy consumption and environmental impact by novel single shot melting process for casting
The CRIMSON (Constrained Rapid Induction Melting Single Shot Up-Casting) method uses a rapid induction furnace to melt just enough metal for a single mould rather than bulk melting used in traditional casting process. The molten metal is then transferred to a computer – controlled platform to complete the counter-gravity up filling. The highly controlled metal flow is pushed into the mould to finish the pouring and solidification. In the present paper the energy saving capability of CRIMSON approach is compared with conventional sand casting process. The paper focuses on the energy and resource efficiency optimization of casting stages through simulation and life cycle assessment analysis simulation for proposing alternative means for the better performance of such processes. It is proven that the CRIMSON process can produce high quality castings with higher energy efficiency and lower environmental impact
The challenges for energy efficient casting processes
Casting is one of the oldest, most challenging and energy intensive manufacturing processes. A typical modern casting process contains six different stages, which are classified as melting, alloying, moulding, pouring, solidification and finishing respectively. At each stage, high level and precision of process control is required. The energy efficiency of casting process can be improved by using novel alterations, such as the Constrained Rapid Induction Melting Single Shot Up-casting process. Within the present study the energy consumption of casting processes is analyzed and areas were great savings can be achieved are discussed. Lean thinking is used to identify waste and to analyse the energy saving potential for casting industry
Simulation based energy and resource efficient casting process chain selection: a case study
Casting processes are among the most energy intensive manufacturing processes. A typical modern casting process contains different stages, classified as melting-alloying, moulding, pouring, solidification, fettling, machining and finishing respectively. At each stage, large amounts of energy are consumed. Since a number of different casting processes exist, it is not always straightforward which process chain to select among the available ones. Up to now the selection is based on cost criteria. This paper focuses on the different criteria that needs to be considered and how they can be simulated focusing especially on the energy and resource efficiency of casting stages. A disruptive technology that uses a rapid induction furnace to melt just enough metal for a single mould rather than bulk melting used in traditional processing is proposed and validated
Comparison of the environmental impact of the CRIMSON process with normal sand casting process
The CRIMSON process is an alternative process to conventional casting that can be used for small to medium batch sizes. The aim of this process are to improve the casting quality and reduce the energy consumption within light-metal casting industry. Nowadays, the energy efficiency becomes more and more important. This is not only about the cost of the production, but also about the environmental effect. In this paper, the CRIMSON process will be compared with the conventional sand casting process. The Life cycle assessment (LCA) method will be used to assess the environmental impact of both casting processes
Reduction of Energy Consumption and GHGs Emission in Conventional Sand Casting Process by Application of a New CRIMSON Process
In conventional foundry, engineers generally consider the quality of casting part as the most essential issue and regard the energy consumption and Green House Gas (GHGs) emission as the auxiliary ones. This usually causes large amount of energy consumption as a result of the inefficient casting processes used and increases the production costs and environmental pollution. This paper presents the new CRIMSON process where its facility and melting process were compared with conventional melt furnaces and aluminium alloy melting process. An actual case was investigated to reveal quantitatively how the conventional foundry wastes energy and increases GHGs emission, and what the improvement of energy efficiency and the GHGs emission reduction can be achieved using the new CRIMSON process. The results of this investigation will help the foundry engineer recognize the importance of energy saving and environmental protection and show how to utilise this new process to reduce production costs and carbon footprint without decreasing the quality of the cast part